hyundai r160lc 3

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FOREWORD

1. STRUCTUREThis service manual has been prepared as an aid to improve the quality of repairs by giving theserviceman an accurate understanding of the product and by showing him the correct way to performrepairs and make judgements. Make sure you understand the contents of this manual and use it tofull effect at every opportunity.This service manual mainly contains the necessary technical information for operations performed ina service workshop.For ease of understanding, the manual is divided into the following sections.

SECTION 1 GENERALThis section explains the safety hints and gives the specification of the machine and majorcomponents.

SECTION 2 STRUCTURE AND FUNCTIONThis section explains the structure and function of each component. It serves not only to give anunderstanding of the structure, but also serves as reference material for troubleshooting.

SECTION 3 HYDRAULIC SYSTEMThis section explains the hydraulic circuit, single and combined operation.

SECTION 4 ELECTRICAL SYSTEMThis section explains the electrical circuit, monitoring system and each component. It serves notonly to give an understanding electrical system, but also serves as reference material for troubleshooting.

SECTION 5 MECHATRONICS SYSTEMThis section explains the computer aided power optimization system and each component.

SECTION 6 TROUBLESHOOTINGThis section explains the troubleshooting charts correlating problems to causes.

SECTION 7 MAINTENANCE STANDARDThis section gives the judgement standards when inspecting disassembled parts.SECTION 8 DISASSEMBLY AND ASSEMBLYThis section explains the order to be followed when removing, installing, disassembling or assemblingeach component, as well as precautions to be taken for these operations.

The specifications contained in this shop manual are subject to change at any time and without anyadvance notice. Contact your HYUNDAI distributor for the latest information.

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Revised edition mark()When a manual is revised, an edition mark isrecorded on the bottom outside corner of thepages.

RevisionsRevised pages are shown at the list of revisedpages on the between the contents page andsection 1 page.

SymbolsSo that the shop manual can be of amplepractical use, important places for safety andquality are marked with the following symbols.

2. HOW TO READ THE SERVICE MANUALDistribution and updatingAny additions, amendments or other changeswill be sent to HYUNDAI distributors.Get the most up-to-date information before youstart any work.

Filing methodSee the page number on the bottom of thepage. File the pages in correct order.Following examples shows how to read the page number.Example 1 2 - 3

Item number(2. Structure andFunction)Consecutive page number foreach item.

Additional pages : Additional pages areindicated by a hyphen(-) and number after thepage number. File as in the example.

1.

2.

3.

Symbol Item Remarks

Special safety precautions arenecessary when performing thework.

Extra special safety precautionsare necessary when performingthe work because it is underinternal pressure.

Special technical precautions orother precautions for preservingstandards are necessary whenperforming the work.

Safety

Caution

10 - 410 - 4 - 110 - 4 - 210 - 5

Added pages

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3. CONVERSION TABLEMethod of using the Conversion TableThe Conversion Table in this section is provided to enable simple conversion of figures. For details ofthe method of using the Conversion Table, see the example given below.

ExampleMethod of using the Conversion Table to convert from millimeters to inchesConvert 55mm into inches.

Locate the number 50in the vertical column at the left side, take this as , then draw a horizontal line from .

Locate the number 5in the row across the top, take this as , then draw a perpendicular line down from .

Take the point where the two lines cross as . This point gives the value when converting from millimeters to inches. Therefore, 55mm = 2.165 inches.

Convert 550mm into inches.

The number 550 does not appear in the table, so divide by 10(Move the decimal point one placeto the left) to convert it to 55mm.Carry out the same procedure as above to convert 55mm to 2.165 inches.

The original value(550mm) was divided by 10, so multiply 2.165 inches by 10(Move the decimalpoint one place to the right) to return to the original value. This gives 550mm = 21.65 inches.

1.

2.

(1)

(2)

(3)

(1)

(2)(3)

Millimeters to inches 1mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.35410 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.74820 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.14230 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.53640 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.32360 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.71770 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.11080 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.50490 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

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Millimeters to inches 1mm = 0.03937in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.35410 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.74820 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.14230 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.53640 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.32360 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.71770 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.11080 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.50490 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1kg = 2.2046lb

0 1 2 3 4 5 6 7 8 9

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.8410 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.8920 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.9330 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.9840 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.0760 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.1270 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.1780 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.2190 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

0-5

Liter to U.S. Gallon 1 = 0.2642 U.S.Gal

3

0 1 2 3 4 5 6 7 8 9

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.37810 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.01920 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.66130 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.30340 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.58660 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.22870 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.87080 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.51190 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153

Liter to U.K. Gallon 1 = 0.21997 U.K.Gal

0 1 2 3 4 5 6 7 8 9

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.98010 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.17920 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.37930 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.57940 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.97860 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.17870 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.37880 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.57790 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

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kgm to lbft 1kgm = 7.233lbft

0 1 2 3 4 5 6 7 8 9

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.110 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.420 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.830 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.140 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.860 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.170 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.480 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.790 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

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kg/cm2 to lb/in2 1kg / cm2 = 14.2233 lb / in2

0 1 2 3 4 5 6 7 8 9

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.010 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.220 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.530 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.740 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.260 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.470 995.6 1010 1024 1038 1053 1067 1081 1095 1109 112480 1138 1152 1166 1181 1195 1209 1223 1237 1252 126690 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

TEMPERATURE

Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verseis to enter the accompanying table in the center or boldface column of figures.These figures refer to the temperature in either Fahrenheit or Centigrade degrees.If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table ofFahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table ofCentigrade values, and read the corresponding Fahrenheit temperature on the right.

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C F C F C F C F

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81

117.8-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4-26.7 -16 3.2 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2-20.6 -5 23.0 -1.1 35 95.0 21.1 70 158.0 51.7 125 257.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0

FOLLOW SAFE PROCEDURE

Unsafe work practices are dangerous. Understandservice procedure before doing work; Do not attemptshortcuts.

WEAR PROTECTIVE CLOTHINGWear close fitting clothing and safety equipmentappropriate to the job.

WARN OTHERS OF SERVICE WORKUnexpected machine movement can cause seriousinjury.Before performing any work on the excavator, attach aDo Not Operatetag on the right side control lever.

USE HANDHOLDS AND STEPSFalling is one of the major causes of personal injury.When you get on and off the machine, always maintaina three point contact with the steps and handrails andface the machine. Do not use any controls ashandholds.Never jump on or off the machine. Never mount ordismount a moving machine.Be careful of slippery conditions on platforms, steps,and handrails when leaving the machine.

SECTION 1 GENERALGROUP 1 SAFETY

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WARN

DONOTOPERATE

PREPARE FOR EMERGENCIESBe prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulanceservice, hospital, and fire department near yourtelephone.

PROTECT AGAINST FLYING DEBRISGuard against injury from flying pieces of metal ordebris; Wear goggles or safety glasses.

PROTECT AGAINST NOISEProlonged exposure to loud noise can causeimpairment or loss of hearing.

Wear a suitable hearing protective device such as ear-muffs or earplugs to protect against objectionable oruncomfortable loud noises.

AVOID POWER LINESSerious injury or death can result from contact withelectric lines.

Never move any part of the machine or load closer toelectric line than 3m(10ft) plus twice the line insulatorlength.

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KEEP RIDERS OFF EXCAVATOROnly allow the operator on the excavator. Keep ridersoff.

Riders on excavator are subject to injury such as beingstruck by foreign objects and being thrown off theexcavator. Riders also obstruct the operator's viewresulting in the excavator being operated in an unsafemanner.

MOVE AND OPERATE MACHINE SAFELYBystanders can be run over. Know the location ofbystanders before moving, swinging, or operating themachine.

Always keep the travel alarm in working condition. Itwarns people when the excavator starts to move.

Use a signal person when moving, swinging, oroperating the machine in congested areas. Coordinatehand signals before starting the excavator.

OPERATE ONLY FORM OPERATOR'S SEATAvoid possible injury machine damage. Do not startengine by shorting across starter terminals.

NEVER start engine while standing on ground. Startengine only from operator's seat.

PARK MACHINE SAFELYBefore working on the machine:

Park machine on a level surface.Lower bucket to the ground.Turn auto idle switch off.Run engine at 1/2 speed without load for 2 minutes.Turn key switch to OFF to stop engine. Remove key

from switch.Move pilot control shutoff lever to locked position.Allow engine to cool.

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SUPPORT MACHINE PROPERLYAlways lower the attachment or implement to theground before you work on the machine. If you mustwork on a lifted machine or attachment, securelysupport the machine or attachment.

Do not support the machine on cinder blocks, hollowtiles, or props that may crumble under continuous load.Do not work under a machine that is supported solely bya jack. Follow recommended procedures in this manual.

SERVICE COOLING SYSTEM SAFELYExplosive release of fluids from pressurized coolingsystem can cause serious burns.

Shut off engine. Only remove filler cap when coolenough to touch with bare hands.

HANDLE FLUIDS SAFELY-AVOID FIRES Handle fuel with care; It is highly flammable. Do notrefuel the machine while smoking or when near openflame or sparks. Always stop engine before refuelingmachine.Fill fuel tank outdoors.

Store flammable fluids away from fire hazards. Do notincinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, anddebris.

Do not store oily rags; They can ignite and burnspontaneously.

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BEWARE OF EXHAUST FUMESPrevent asphyxiation. Engine exhaust fumes cancause sickness or death.

If you must operate in a building, be positive there isadequate ventilation. Either use an exhaust pipeextension to remove the exhaust fumes or open doorsand windows to bring enough outside air into the area.

REMOVE PAINT BEFORE WELDING OR HEATINGAvoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint isheated by welding, soldering, or using a torch.

Do all work outside or in a well ventilated area.Dispose of paint and solvent properly.

Remove paint before welding or heating:

If you sand or grind paint, avoid breathing the dust.Wear an approved respirator.

If you use solvent or paint stripper, remove stripperwith soap and water before welding. Removesolvent or paint stripper containers and otherflammable material from area. Allow fumes todisperse at least 15 minutes before welding orheating.

ILLUMINATE WORK AREA SAFELYIlluminate your work area adequately but safely. Use aportable safety light for working inside or under themachine. Make sure the bulb is enclosed by a wirecage. The hot filament of an accidentally broken bulbcan ignite spilled fuel or oil.

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SERVICE MACHINE SAFELYTie long hair behind your head. Do not wear a necktie,scarf, loose clothing or necklace when you work nearmachine tools or moving parts. If these items were toget caught, severe injury could result.Remove rings and other jewelry to prevent electricalshorts and entanglement in moving parts.

STAY CLEAR OF MOVING PARTSEntanglements in moving parts can cause seriousinjury.To prevent accidents, use care when working aroundrotating parts.

AVOID HIGH PRESSURE FLUIDSEscaping fluid under pressure can penetrate the skincausing serious injury.Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protecthands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Anyfluid injected into the skin must be surgically removedwithin a few hours or gangrene may result.

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AVOID HEATING NEAR PRESSURIZED FLUIDLINESFlammable spray can be generated by heating nearpressurized fluid lines, resulting in severe burns toyourself and bystanders. Do not heat by welding,soldering, or using a torch near pressurized fluid lines orother flammable materials.

Pressurized lines can be accidentally cut when heatgoes beyond the immediate flame area. Install fireresisting guards to protect hoses or other materials.

PREVENT BATTERY EXPLOSIONSKeep sparks, lighted matches, and flame away from thetop of battery. Battery gas can explode.

Never check battery charge by placing a metal objectacross the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; It may explode. Warmbattery to 16C(60F).

PREVENT ACID BURNSSulfuric acid in battery electrolyte is poisonous. It isstrong enough to burn skin, eat holes in clothing, andcause blindness if splashed into eyes.

Avoid the hazard by:1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is added.4. Avoiding spilling of dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:1. Flush your skin with water.2. Apply baking soda or lime to help neutralize the

acid.3. Flush your eyes with water for 10-15 minutes. Get

medical attention immediately.

If acid is swallowed:1. Drink large amounts of water or milk.2. Then drink milk of magnesia, beaten eggs, or

vegetable oil.3. Get medical attention immediately.

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USE TOOLS PROPERLYUse tools appropriate to the work. Makeshift tools,parts, and procedures can create safety hazards.

Use power tools only to loosen threaded tools andfasteners.

For loosening and tightening hardware, use the correctsize tools. DO NOT use U.S. measurement tools onmetric fasteners. Avoid bodily injury caused by slippingwrenches.

Use only recommended replacement parts.(See Partscatalogue.)

DISPOSE OF FLUIDS PROPERLYImproperly disposing of fluids can harm the environmentand ecology. Before draining any fluids, find out theproper way to dispose of waste from your localenvironmental agency.Use proper containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.DO NOT pour oil into the ground, down a drain, or into astream, pond, or lake. Observe relevant environmentalprotection regulations when disposing of oil, fuel,coolant, brake fluid, filters, batteries, and other harmfulwaste.

REPLACE SAFETY SIGNSReplace missing or damaged safety signs. See themachine operator's manual for correct safety signplacement.

LIVE WITH SAFETYBefore returning machine to customer, make suremachine is functioning properly, especially the safetysystems. Install all guards and shields.

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1-9

1. MAJOR COMPONENT

GROUP 2 SPECIFICATIONS

Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight

Side cutter

Bucket cylinder Connecting link

Connecting rod

Idler

Track roller

Carrier roller

Track

Sprocket

Travel motor

Tooth Turning jointBucket Swing motor Main control valve Oil cooler

Fuel tankTool box Hydraulic oil tank Main pump

Engine

Radiator

1-10

2. SPECIFICATIONROBEX 160LC-31)

Operating weightBucket capacity(PCSA heaped), standardOverall lengthOverall width, with 600mm shoeOverall height Superstructure widthOverall height of cabGround clearance of counterweightEngine cover heightMinimum ground clearanceRear-end distanceRear-end swing radiusDistance between tumblersUndercarriage lengthUndercarriage widthTrack gaugeTrack shoe width, standardTravel speed(Low/high)Swing speedGradeabilityGround pressure(600mm shoe)

kg(lb)m3(yd3)

mm(ft-in)

km/hr(mph)rpm

Degree(%)kg/cm2(psi)

Specification

16600(36600)0.65(0.85)8530(28' 0")2590( 8' 6")2870( 9' 5")2470( 8' 1")2850( 9' 4")1035( 3' 5")2135( 7' 0")460( 1' 6")

2400( 7'10")2490( 8' 2")3190(10' 6")3980(13' 1")2590( 8' 6")1990( 6' 6")600(24")

3.5/5.5(2.2/3.4)12.1

35(70)0.40(5.69)

UnitDescription

A

B

CD

E

F

GH

I

I'

JK

L

M

N

C

AKJ

I(I')

FG

E

H

D

M

B(L)N

1-11

3. WORKING RANGE5.10m(16' 9") BOOM1)

A

D

A'F

EB B

' C

8ft

[ ] : Power boost

Max digging reach Max digging reach on ground Max digging depthMax digging depth (8ft level) Max vertical wall digging depthMax digging heightMax dumping heightMin swing radius

Bucket digging force

Arm crowd force

Description 2.25m(7' 5") ArmAA'BB'CDEF

8630mm8470mm5740mm5480mm4930mm8750mm6120mm2960mm

(28' 4")(27' 9")(18'10")(18' 0")(16' 2")(28' 8")(20' 1")( 9' 9")

90 [99]9200 [10060]

20280 [22180]104 [113]

10570 [11560]23300 [25480]

78 [85] 7920 [8660]

17460 [19100] 81 [89]

8260 [9030]18210 [19920]

2.60m(8' 6") Arm8950mm8800mm6090mm5860mm5370mm8940mm6310mm2920mm

(29' 4")(28'10")(20' 0")(19' 3")(17' 7")(29' 4")(20' 8")( 9' 7")

3.10m(10' 2") Arm9340mm9200mm6590mm6360mm5580mm9000mm6400mm2940mm

(30' 8")(30' 2")(21' 7")(20'10")(18' 4")(29' 6")(21' 0")( 9' 8")

90 [99]9200 [10060]

20280 [22180]104 [113]

10570 [11560]23300 [25480]

70 [76]7110 [7780]

15670 [17140]73 [79]

7390 [8080]16290 [17820]

90 [99]9200 [10060]

20280 [22180]104 [113]

10570 [11560]23300 [25480]

63 [69]6440 [7040]

14200 [15530]65 [71]

6650 [7270]14660 [16030]

SAE

ISO

SAE

ISO

kNkgflbfkNkgflbfkNkgflbfkNkgflbf



1-12

4. WEIGHTR160LC-31)

Upperstructure assembly

Main frame weld assembly

Engine assembly

Main pump assembly

Main control valve assembly

Swing motor assembly

Hydraulic oil tank assembly

Fuel tank assembly

Counterweight

Cab assembly

Lower chassis assembly

Track frame weld assembly

Swing bearing

Travel motor assembly

Turning jointTrack recoil spring and idler

Idler

Carrier roller

Track roller

Track-chain assembly(600mm standard triple grouser shoe)Front attachment assembly(5.10m boom, 2.60m arm, 0.65m3 PCSA heaped bucket)5.10m boom assembly

2.60m arm assembly

0.65m3 PCSA heaped bucket

Boom cylinder assembly

Arm cylinder assembly

Bucket cylinder assembly

Bucket control link assembly

Item

7220

1210

410

125

135

218

145

110

2900

275

6450

2005

230

210

36

137

160

21

38

1183

2930

1035

525

510

135

183

125

112

kg lb15920

2670

904

276

298

481

320

243

6390

610

14220

4420

507

463

79

302

353

46

84

2610

6460

2280

1157

1124

298

403

276

247

R160LC-3

1- 13

5. LIFTING CAPACITIESROBEX 160LC-3

5.10m(16' 9") boom, 2.60m(8' 6") arm equipped with 0.65m3(PCSA heaped) bucket and 600mm(24") triple grouser shoe.

1)(1)

: Rating over-front : Rating over-side or 360 degree

Note 1. Lifting capacity are based on SAE J1097 and ISO 10567.2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine

on firm, level ground or 87% of full hydraulic capacity. 3. The load point is a hook located on the back of the bucket. 4. *indicates load limited by hydraulic capacity.

Load point height

Load radius At max. reach1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach

7.5m kg *2800 *2800 6.20(25ft) lb *6170 *6170 (20.3)6.0m kg *2620 *2620 *2800 2040 7.46(20ft) lb *5780 *5780 *6170 4500 (24.5)4.5m kg *3220 2910 2810 1660 8.20(15ft) lb *7100 6420 6190 3660 (26.9)3.0m kg *6720 *6720 *4530 4420 *3670 2760 *2400 1840 2550 1470 8.56(10ft) lb *14820 *14820 *9990 9740 *8090 6080 *5290 4060 5620 3240 (28.1)1.5m kg *7670 7470 *5690 4050 *4210 2590 3060 1770 2480 1410 8.61(5ft) lb *16910 16470 *12540 8930 *9280 5710 6750 3900 5470 3110 (28.2)

-1.5m kg *6100 *6100 *9750 7060 *6600 3690 4190 2390 2900 1660 7.73(-5ft) lb *13450 *13450 *21500 15560 *14550 8140 9240 5270 6390 3660 (25.4)

-3.0m kg *9050 *9050 *9000 7170 *6070 3720 4220 2410 *3280 2160 6.66(-10ft) lb *19950 *19950 *19840 15810 *13380 8200 9300 5310 *7230 4760 (21.9)-4.5m kg *6610 *6610 *4370 3890(-15ft) lb *14570 *14570 *9630 8580

m(ft)

Ground kg *7280 7100 *6450 3800 4270 2450 *2970 1710 2570 1460 8.34Line lb *16050 15650 *14220 8380 9410 5400 *6550 3770 5670 3220 (27.4)

1- 14

Load point height

Load radius At max. reach1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach

m(ft)7.5m kg *3040 *3040 5.71(25ft) lb *6700 *6700 (18.7)6.0m kg *3020 2260 7.08(20ft) lb *6660 4980 (23.2)4.5m kg *3870 *3870 *3490 2900 3030 1810 7.86(15ft) lb *8530 *8530 *7690 6390 6680 3990 (25.8)3.0m kg *7610 *7610 *4900 4390 *3910 2760 2740 1610 8.24(10ft) lb *16780 *16780 *10800 9680 *8620 6080 6040 3550 (27.0)1.5m kg *5740 *5740 *5990 4030 *4410 2610 2660 1540 8.28(5ft) lb *12650 *12650 *13210 8880 *9720 5750 5860 3400 (27.2)

-1.5m kg *6620 *6620 *9920 7150 *6600 3750 4250 2440 3170 1850 7.37(-5ft) lb *14590 *14590 *21870 15760 *14550 8270 9370 5380 6990 4080 (24.2)

-3.0m kg *10180 *10180 *8540 7300 *5870 3800 *3370 2470 6.22(-10ft) lb *22440 *22440 *18830 16090 *12940 8380 *7430 5450 (20.4)-4.5m kg *5730 *5730(-15ft) lb *12630 *12630


(2)


(3)

Ground kg *6990 *6990 *6610 3820 4300 2490 2780 1610 8.01Line lb *15410 *15410 *14570 8420 9480 5490 6130 3550 (26.3)

Load point height

Load radius At max. reach1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach

7.5m kg *2480 *2480 6.76(25ft) lb *5470 *5470 (22.2)6.0m kg *2580 *2580 *2530 1850 7.92(20ft) lb *5690 *5690 *5580 4080 (26.0)4.5m kg *2880 *2880 *1840 *1840 2590 1520 8.61(15ft) lb *6350 *6350 *4060 *4060 5710 3350 (28.2)3.0m kg *4030 *4030 *3370 2800 *2750 1870 2360 1350 8.95(10ft) lb *8880 *8880 *7430 6170 *6060 4120 5200 2980 (29.4)1.5m kg *8730 7710 *5280 4120 *3960 2610 3070 1780 2290 1290 9.00(5ft) lb *19250 17000 *11640 9080 *8730 5750 6770 3920 5050 2840 (29.5)

-1.5m kg *5830 *5830 *9570 6970 *6550 3660 4160 2360 2620 1480 8.17(-5ft) lb *12850 *12850 *21100 15370 *14440 8070 9170 5200 5780 3260 (26.8)

-3.0m kg *8220 *8220 *9510 7020 *6270 3640 4150 2350 *3230 1870 7.18(-10ft) lb *18120 *18120 *20970 15480 *13820 8020 9150 5180 *7120 4120 (23.6)-4.5m kg *11360 *11360 *7600 7240 *5090 3750(-15ft) lb *25040 *25040 *16760 15960 *11220 8270

m(ft)

Ground kg *8130 7110 *6200 3810 4270 2450 2990 1700 2370 1330 8.75Line lb *17920 15670 *13670 8400 9410 5400 6590 3750 5220 2930 (28.7)

1-15

6. BUCKET SELECTION GUIDEGENERAL BUCKET1)

PCSAheaped

0.39m3(0.51yd3)

0.57m3(0.75yd3)

0.65m3(0.85yd3)

0.70m3(0.92yd3)

0.80m3(1.05yd3)

CECEheaped

0.35m3(0.46yd3)

0.50m3(0.65yd3)

0.55m3(0.72yd3)

0.60m3(0.78yd3)

0.70m3(0.92yd3)

Withoutside cutter

620mm(24")

840mm(33")

930mm(37")

990mm(39")

1080mm(43")

Withside cutter

740mm(29")

960mm(38")

1050mm(41")

1110mm(44")

1200mm(47")

410kg(900lb)

490kg(1080lb)

510kg(1120lb)

540kg(1190lb)

570kg(1260lb)

2.25m arm(7' 5")

2.60m arm(8' 6")

3.10m arm(10' 2")

Recommendation5.10m (16' 9") boomCapacity Width

Weight

0.39m3 PCSAheaped bucket





Applicable for materials with density of 2000kg/m3 (3370lb/yd3) or lessApplicable for materials with density of 1600kg/m3 (2700lb/yd3) or lessApplicable for materials with density of 1100kg/m3 (1850lb/yd3) or less

Standard bucket

1-16

7. UNDERCARRIAGETRACKSX-leg type center frame is integrally welded with reinforced box-section track frames. The designincludes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shockabsorbing springs and assembled track-type tractor shoes with triple grousers.

TYPES OF SHOES

NUMBER OF ROLLERS AND SHOES ON EACH SIDE3)

1)

2)

mm(in)kg(lb)

kg/cm2(psi)mm(ft-in)

600(24)16600(36600)

0.40(5.69)2590(8' 6")

700(28)16970(37410)

0.35(4.98)2690(8' 10")

800(32)17240(38010)

0.31(4.41)2790(9' 2")

500(20)16360(36070)

0.47(6.68)2490(8' 2")

Triple grouser

Shapes

Shoe widthOperating weightGround pressureOverall width

R160LC-3

Model

Carrier rollersTrack rollers

Track shoes

2EA

7EA

49EA

Item Quantity

1-17

8. SPECIFICATIONS FOR MAJOR COMPONENTSENGINE1)

MAIN PUMP

Item

Model

Type

Cooling methodNumber of cylinders and arrangementFiring orderCombustion chamber typeCylinder borestrokePiston displacementCompression ratioRated gross horse power(SAE J1349) Maximum torque at 1500rpmEngine oil quantityDry weightHigh idling speedLow idling speedRated fuel consumption Starting motorAlternator

Battery

Specification

Cummins B3.9-C4-cycle turbocharged, after cooled and low emissiondiesel engineWater cooling4 cylinders, in-line1-3-4-2Direct injection type102120mm(4.02"4.72")3900cc(238cu in)16.5 : 1110Hp at 2200rpm(82kW at 2200rpm)45.9kgfm(332lbfft)11(2.9U.S. gal)329kg(725lb)2450*50rpm950100rpm169.9g/PshrDelco Remy 28MT(24V)DAC(24V - 60AMP)212V100Ah

Item

TypeCapacityMaximum pressureRated oil flowRated speed

Specification

Variable displacement tandem axis piston pumps264cc/rev320kgf/cm2(4550psi)[350kgf/cm2(4980psi)]2140/min (40U.S. gpm/ 30.8U.K. gpm)2200rpm

2)

[ ] : Power boost

1-18

GEAR PUMP

MAIN CONTROL VALVE

SWING MOTOR

TRAVEL MOTOR

Item

TypeCapacityMaximum pressureRated oil flow

Specification

Fixed displacement gear pump single stage10cc/rev40kgf/cm2(570psi)22/min(5.8U.S. gpm/4.8U.K. gpm)

Item

TypeOperating methodMain relief valve pressureOverload relief valve pressure

Specification

9 spools two-blockHydraulic pilot system320kgf/cm2(4550psi)[350kgf/cm2(4980psi)]380kgf/cm2(5405psi)

Item

TypeCapacityRelief pressureBraking systemBraking torqueBrake release pressureReduction gear typeSwing speed

Specification

Fixed displacement axial piston motor99.2cc/rev260kgf/cm2(3911psi)Automatic, spring applied, hydraulic released42kgfm(304lbfft)4.5~20kgf/cm2(64~284psi)2 - stage planetary12.1rpm

Item

TypeRelief pressureCapacity(max / min)Reduction gear typeBraking systemBrake release pressureBraking torque

Specification

Variable displacement axial piston motor350kgf/cm2(4980psi)87.3/55.5cc/rev3-stage planetaryAutomatic, spring applied, hydraulic released11kgf/cm2(156psi)1060~1780kgfm(7667~12874lbfft)

[ ] : Power boost

3)

4)

5)

6)

1-19

REMOTE CONTROL VALVE

CYLINDER

SHOE

Item

Type

Specification

Pressure reducing type5.5kgf/cm2(78psi)19.5kgf/cm2(277psi)82.7mm(3.3in)123mm(4.8in)

Operating pressureMinimum

Maximum

Lever

PedalSingle operation stroke

Item Specification

110801180mmExtend only120851320mmExtend and retract105751005mmExtend only

Bore diaRod diaStrokeCushionBore diaRod diaStrokeCushionBore diaRod diaStrokeCushion

Boom cylinder

Arm cylinder

Bucket cylinder

Item Width

600mm(24")500mm(20") 700mm(28")800mm(32")

Ground pressure

0.40kgf/cm2(5.69psi)0.47kgf/cm2(6.68psi)0.35kgf/cm2(4.98psi)0.31kgf/cm2(4.41psi)

Link quantity

49494949

Overall width

2590mm( 8' 6")2490mm( 8' 2")2690mm( 8' 10")2790mm( 9' 2")

STD

OPT

9)

7)

8)

BUCKETCapacity

PCSA heaped CECE heaped Without side cutter With side cutterWidth

Item Tooth quantity

STD

OPT

0.65m3(0.85yd3)0.39m3(0.51yd3)0.57m3(0.75yd3)0.70m3(0.92yd3)0.80m3(1.05yd3)

0.55m3(0.72yd3)0.35m3(0.46yd3)0.50m3(0.65yd3)0.60m3(0.78yd3)0.70m3(0.92yd3)

5

34

5

5

930mm(37")620mm(24")840mm(33")990mm(39")

1080mm(43")

1050mm(41")740mm(29")960mm(38")

1110mm(44")1200mm(47")

10)

1-20

9. RECOMMENDED OILSUse only oils listed below or equivalent.Do not mix different brand oil.

Capacity(U.S. gal)Service point Kind of fluid

Engine oil 11(2.9)

Hydraulic tank Hydraulic oil

Gear oil

Fuel tank Diesel fuel 250(66.1)

Ambient temperatureC(F)

Ethylene glycol base permanent type

Engineoil pan

Fitting(Grease nipple)

Radiator(Reservoir tank)

Grease As required

Tank; 120(31.7)System;210(55.5)

24(6.3)

-20 -10 0 10 20 30 40(-4) (14) (32) (50) (68) (86) (104)

SAE : Society of Automotive Engineers API : American Petroleum Institute ISO : International Organization for Standardization NLGI : National Lubricating Grease Institute ASTM : American Society of Testing and Material

Mixture of antifreezeand water

50 : 50

SAE 30

SAE 10W

SAE 10W-30

SAE 15W-40

SAE 85W-140

ISO VG 32

ASTM D975 NO.1

ASTM D975 NO.2

NLGI NO.1

NLGI NO.2

ISO VG 46

ISO VG 68

3.4(0.9)4.42

(1.22)

Swing drive

Final drive

2 - 1

1. STRUCTUREThe pump device consists of main pump, regulator and gear pump.

SECTION 2 STRUCTURE AND FUNCTIONGROUP 1 PUMP DEVICE

RegulatorQmin Adjusting screw Qmax Adjusting screw

Rear pumpValve blockFront pump

Pi2

a4

Dr

Pi1

Qmin Adjusting screwRegulator

Pilot pump

PfA3

B3

B3

B1

Pi1

DrDr

Pi2

a1 a2

a3

Pi1

A1 A2

B1 B3 a3

Pi2

a4

Hydraulic circuit

a1 a2

DrA3

Pf

Front RearPort

A1,2B1Dr

Pf

Pi1,i2a1,2,3,4

A3B3

Port name

Delivery portSuction portDrain port

Power shift port(For decreasing)

Pilot portGauge port

Gear pump delivery portGear pump suction port

Port size

SAE6000psi 3/4"SAE2500psi 2 1/2"

PF 1/2 - 19

PF 1/4 - 15

PF 1/4 - 15PF 1/4 - 15PF 1/2 - 19

PF 3/4 - 20.5

2 - 2

MAIN PUMPThe main pump consists of two piston pumps(Front & rear) and valve block.

1)

04 Gear pump111 Drive shaft(F)113 Drive shaft(R)114 Spline123 Roller bearing124 Needle bearing127 Bearing spacer141 Cylinder block151 Piston152 Shoe153 Push plate156 Bushing157 Cylinder spring158 Spacer211 Shoe plate212 Swash plate214 Bushing251 Swash plate support

261 Seal cover(F)271 Pump casing312 Valve block313 Valve plate(R)314 Valve plate(L)401 Hexagon socket bolt406 Hexagon socket bolt435 Flange socket bolt466 VP plug468 VP plug490 VP plug531 Tilting pin532 Servo piston534 Stopper(L)535 Stopper(S)548 Pin702 O-ring710 O-ring

717 O-ring719 O-ring724 O-ring725 O-ring728 O-ring732 O-ring774 Oil seal789 Back up ring792 Back up ring808 Hexagon head nut824 Snap ring885 Pin886 Spring pin901 Eye bolt953 Set screw954 Set screw

532702792214 548 531 724

789732 534 901 808 113211152151717954

535808953886717406261774

212251123710127824111

490 467728

153 156 158 157 141 271 401314885466725

114124312313

04

435

2 - 3

REGULATOR(1/2)2)

753

SECTION B-B

Pf

Pf

D

D

496

AKR36-9N1SP2

Pi

(KDRDE5K) Pf B

AB

BA

405

436

874

611

613615

614858755

612897

875412 735079 722

SECTION D-D

a

755 466

a

699 413 496 438

725724

VIEW C

641 730 643 708 644 645 646 728 924

801

438

Port

ABPiPfP2

Port name

Delivery portSuction port

Pilot portPowershift port

Companion delivery port

Port size

3/4"2 1/2"

PF 1/4-15PF 1/4-15

-

2 - 4

REGULATOR(2/2)

079 Hexagon socket screw405 Hexagon socket screw412 Hexagon socket screw413 Hexagon socket screw436 Hexagon socket screw438 Hexagon socket screw466 Plug496 Plug601 Casing611 Feedback lever612 Lever(1)613 Lever(2)614 Fulcrum plug615 Adjust plug621 Piston622 Piston case623 Compensator rod624 Spring seat(C)625 Outer spring626 Inner spring627 Adjust stem(C)

628 Adjust screw(C)629 Cover(C)630 Nut631 Sleeve641 Pilot cover642 Pilot cover(QMC)643 Pilot piston644 Spring seat(Q)645 Adjust stem(Q)646 Pilot spring651 Sleeve652 Spool653 Spring seat654 Return spring655 Set spring708 O-ring722 O-ring724 O-ring725 O-ring728 O-ring730 O-ring

732 O-ring733 O-ring734 O-ring735 O-ring753 O-ring755 O-ring756 O-ring763 O-ring801 Nut814 Snap ring836 Snap ring858 Snap ring874 Pin875 Pin887 Pin897 Pin898 Pin924 Set screw925 Adjust screw(Q)

734 653 654 836 651 652 601 624 629 630 628

655

641

814

898

631

732

733

622

C

801

925

627

732

621 623 625 626 887 763 756

SECTION A-A

2 - 5

GEAR PUMP3)

307 Poppet308 Seat309 Spring seat310 Spring311 Adjust screw312 Lock nut351 Gear case

353 Drive gear354 Driven gear355 Filter361 Front case433 Flange socket434 Flange socket435 Flange socket

466 Plug700 Ring710 O-ring725 O-ring732 O-ring850 Snap ring

B3

A3

a3

700 354 351

710 435 361 353

433

434

311

312

732 309 307 310 308 434

850355

466,725

2 - 6

Rotary groupThe rotary group consists of drive shaft(F)(111), cylinder block(141), pistonshoes(151,152), set plate(153), sphericalbush(156), spacer(158) and cylinderspring(157). The drive shaft is supportedby bearing(123,124) at its both ends.The shoe is caulked to the piston to froma spherical coupling. It has a pocket torelieve thrust force generated by loadingpressure and the take hydraulic balanceso that it slides lightly over the shoeplate(211). The sub group composed bya piston and a shoe is pressed againstthe shoe plate by the action of thecylinder spring via a retainer and aspherical bush.Similarly, the cylinder block is pressedagainst valve plate(313) by the action ofthe cylinder spring.

Swash plate groupThe swash plate group consists of swashplate(212), shoe plate(211), swash platesupport(251), tilting bush(214), tiltingpin(531) and servo piston(532).The swash plate is a cylindrical partformed on the opposite side of the slidingsurface of the shoe and is supported bythe swash support.If the servo piston moves to the right andleft as hydraulic force controlled by theregulator is admitted to hydraulicchamber located on both sides of theservo piston, the swash plate slides overthe swash plate support via the sphericalpart of the tilting pin to change the tiltingangle( )

2. FUNCTIONMAIN PUMPThe pumps may classified roughly into the rotary group performing a rotary motion and working asthe major part of the whole pump function: The swash plate group that varies the delivery rates: Andthe valve cover group that changes over oil suction and discharge.

1)

(1)

(2)

157

211

211123

111

212

251

532

151152

531548214

124313

141158

156153

2 - 7

Valve block groupThe valve block group consists of valveblock(312), valve plate(313) and valveplate pin(885).The valve plate having two melon-shapedports is fixed to the valve block and feedsand collects oil to and from the cylinderblock.The oil changed over by the valve plate isconnected to an external pipeline by wayof the valve block.Now, if the drive shaft is driven by a primemover(Electric motor, engine, etc), itrotates the cylinder block via a splinelinkage at the same time. If the swashplate is tilted as in Fig(Previous page) thepistons arranged in the cylinder blockmake a reciprocating motion with respectto the cylinder block, while they revolvewith the cylinder block.If you pay attention to a single piston, itperforms a motion away from the valveplate(Oil sucking process) within 180degrees, and makes a motion towardsthe valve plate(Or oil dischargingprocess) in the rest of 180 degrees.When the swash plate has a tilting angleof zero, the piston makes no stroke anddischarges no oil.

(3)

313885

312

2 - 8

Negative flow controlBy changing the pilot pressure Pi, thepump tilting angle(Delivery flow) isregulated arbitrarily, as shown in thefigure.This regulator is of the negative flowcontrol in which the delivery flow Qdecreases as the pilot pressure Pi rises.With this mechanism, when the pilotpressure corresponding to the flowrequired for the work is commanded, thepump discharges the required flow only,and so it does not consume the poweruselessly.

REGULATORRegulator consists of the negative flow control, total horse power control and power shift controlfunction.

2)

(1)

Pilot pressure, Pi

Deliv

ery f

low, Q

2 - 9

Flow reducing function

As the pilot pressure Pi rises, the pilot piston(643) moves to the right to a position where the forceof the pilot spring(646) balances with the hydraulic force.The groove(A) in the pilot piston is fitted with the pin(875) that is fixed to lever 2(613). Therefore,when the pilot piston moves, lever 2 rotates around the fulcrum of point B [fixed by the fulcrumplug(614) and pin(875)]. Since the large hole section(C) of lever 2 contains a protruding pin(897)fixed to the feedback lever(611), the pin(897) moves to the right as lever 2 rotates. Since theopposing-flat section(D) of the feedback lever is fitted with the pin(548) fixed by the tilting pin(531)that swings the swash plate, the feedback lever rotates around the fulcrum of point D, as thepin(897) moves.Since the feedback lever is connected with the spool(652) via the pin(874), the spool moves tothe right.The movement of the spool causes the delivery pressure P1 to connect to port CL through thespool and to be admitted to the large diameter section of the servo piston. The delivery pressureP1 that is constantly admitted to the small diameter section of the servo piston moves the servopiston to the right due to the area difference, resulting in decrease of the tilting angle.When the servo piston moves to the right, point D also moves to the right. The spool is fittedwith the return spring(654) and is tensioned to the left at all times, and so the pin(897) is pressedagainst the large hole section(C) of lever 2.Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and thespool is shifted to the left. This causes the opening between the sleeve(651) and spool(652) toclose slowly, and the servo piston comes to a complete stop when it closes completely.

643 654 651 652 613 646

B(E)874897

875

CA

611

CLP1

531

548DSmall diameterchamberServo pistonLarge diameter

chamber

2 - 10

Flow increasing function

As the pilot pressure Pi decreases, the pilot piston(643) moves to the left by the action of the pilotspring(646) and causes lever 2(613) to rotate around the fulcrum of point B. Since the pin(897)is pressed against the large hole section(C) of lever 2 by the action of the return spring(654) viathe spool(652), pin(874), and feedback lever(611), the feedback lever rotates around the fulcrumof point D as lever 2 rotates, and shifts the spool to the left. Port CL opens a way to the tankport as the spool moves. This deprives the large diameter section of the servo piston ofpressure, and shifts the servo piston to the left by the discharge pressure P1 in the smalldiameter section, resulting in an increase in the flow rate.As the servo piston moves, point D also moves to the left, the feedback lever rotates around thefulcrum of point C, and the spool moves to the right till the opening between the spool and sleeveis closed.

643 654 651 652 613 646

B(E)874897

875

C

611

CLP1

531

548DSmall diameterchamberServo pistonLarge diameter

chamber

2 - 11

The flow control characteristic can beadjusted with the adjusting screw.Adjust it by loosening the hexagon nut(801) and by tightening(Or loosening) thehexagonal socket head screw(924).Tightening the screw shifts the controlchart to the right as shown in the figure.

Adjusting values are shown in table

Adjustment of flow control characteristic

Pilot pressure, PiDe

liver

y flow

, Q

801924

Adjustment of flow controlcharacteristic

Tightening amount ofadjusting

screw(924)

(Turn)

+1/4

Flow controlstarting

pressure change amount

(kgf/cm2)

+1.5

Flow changeamount

(/min)

+8

Speed

(min -1)

2200

2 - 12

Total horsepower controlThe regulator decreases the pump tiltingangle(Delivery flow) automatically to limitthe input torque within a certain value witha rise in the delivery pressure P1 of theself pump and the delivery pressure P2 ofthe companion pump.(The input horsepower is constant whenthe speed is constant.)Since the regulator is of the simultaneoustotal horsepower type that operates by thesum of load pressures of the two pumpsin the tandem double-pump system, theprime mover is automatically preventedfrom being overloaded, irrespective of theload condition of the two pumps, whenhorsepower control is under way.Since this regulator is of the simultaneoustotal horsepower type, it controls the tiltingangles(Displacement volumes) of the twopumps to the same value as representedby the following equation :Tin = P1q/2 + P2q/2

= (P1+P2)q/2The horsepower control function is thesame as the flow control function and issummarized in the following.(For detailedbehaviors of respective parts, refer to thesection of flow control.)

(2)

Delivery pressure, (P1+P2)

Deliv

ery f

low, Q

2 - 13

Overload preventive function

When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, itacts on the stepped part of the compensating piston(621). It presses the compensating rod(623)to the right till the force of the outer spring(625) and inner spring(626) balances with the hydraulicforce. The movement of the compensating rod is transmitted to lever 1(612) via pin(875).Lever 1 rotates around the pin(875) (E) fixed to the casing(601).Since the large hole section(F) of lever 1 contains a protruding pin(897) fixed to the feedbacklever(611), the feedback lever rotates around the fulcrum of point D as lever 1 rotates, and thenthe spool(652) is shifted to the right. As the spool moves, the delivery pressure P1 is admitted tothe large diameter section of the servo piston via port CL, causes the servo piston move to theright, reduces the pump delivery, flow rate, and prevents the prime mover from being overloaded.The movement of the servo piston is transmitted to the feedback lever via point D. Then thefeedback lever rotates around the fulcrum of point F and the spool is shifted to the left. Thespool moves till the opening between the spool(652) and sleeve(651) is closed.

621 651 652 623 612 601 625 626

B(E)897

875

F

611

CLP1

P2 P1

DSmall diameterchamber

Servo pistonLarge diameterchamber

2 - 14

Flow reset function

As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases,the compensating rod(623) is pushed back by the action of the springs(625 & 626) to rotate lever1(612) around point E. Rotating of lever 1 causes the feedback lever(611) to rotate around thefulcrum of point D and then the spool(652) to move to the left. As a result, port CL opens a wayto the tank port.This causes the servo piston to move to the left and the pump's delivery rate to increase.The movement of the servo piston is transmitted to the spool by the action of the feedbackmechanism to move it till the opening between the spool and sleeve is closed.

621 651 652 623 612 601 625 626

B(E)897

875

F

CLP1

P2 P1

DSmall diameterchamberServo piston

Large diameterchamber

2 - 15

Adjustment of outer springAdjust it by loosening the hexagonnut(630) and by tightening(Or loosening)the adjusting screw C(628). Tighteningthe screw shifts the control chart to theright and increases the inputhorsepower as shown in the figure.Since turning the adjusting screw C by Nturns changes the setting of the innerspring(626), return the adjusting screwQI(925) by NA turns at first.(A=2.2)Adjusting values are shown in table

Low tilting angle(Low flow) command preferential functionAs mentioned above, flow control and horsepower control tilting angle commands are transmittedto the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2. However,since sections C and F have the pins(4) protruding from the large hole(8), only the leverlessening the tilting angle contacts the pin(897) ; The hole(8) in the lever of a larger tilting anglecommand is freed without contacting the pin(897). Such a mechanical selection method permitspreference of the lower tilting angle command of the flow control and horsepower control.

Adjustment of input horsepowerSince the regulator is of total cumulative horsepower type, adjust the adjusting screws of both thefront and rear pumps, when changing the horsepower set values. The pressure change valuesby adjustment are based on two pumps pressurized at the same time, and the values will bedoubled when only one pump is loaded.

a.


Deliv

ery f

low, Q

625 626 630 628

801

925

Adjustment of outer springTightening amount ofadjustingscrew(C)

(628)

(Turn)

+1/4

Compens-ating control

starting pressurechangeamount

(kgf/cm2)

+19

Input torquechangeamount

(/min)

+3

Speed

(min -1)

2200

2 - 16

Adjustment of inner springAdjust it by loosening the hexagon nut(801) and by tightening(Or loosening)the adjusting screw QI(925).Tightening the screw increases the flowand then the input horsepower asshown in the figure.

Adjusting valves are shown in table

b.


Deliv

ery f

low, Q

626

801

925

Adjustment of inner springTightening amount ofadjustingscrew(QI)

(925)

(Turn)

+1/4

Flow control starting

pressurechangeamount

(kgf/cm2)

+27

Input torquechangeamount

(/min)

+2.5

Speed

(min -1)

2200

2 - 17

Power shift control

The set horsepower valve is shifted byvarying the command current level of theproportional pressure reducing valveattached to the pump.Only one proportional pressure reducingvalve is provided.However, the secondary pressure Pf(power shift pressure) is admitted to thehorsepower control section of each pumpregulator through the pump's internal pathto shift it to the same set horsepower level.This function permits arbitrary setting of the pump output power, thereby providing the optimumpower level according to the operating condition.The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shownin the figure.As the power shift pressure Pf rises, the compensating rod(623) moves to the right via thepin(898) and compensating piston(621).This decreases the pump tilting angle and then the set horsepower in the same way as explainedin the overload preventive function of the horsepower control. On the contrary, the sethorsepower rises as the power shift pressure Pf falls.

(3)


Deliv

ery f

low, Q

Pf=MAX

Pf=MIN

621 651 652 623 612 625 626

B(E)897

875

898

611

F

CLP1

P2

Pf

P1

DSmall diameterchamberServo piston

Large diameterchamber

2 - 18

Adjustment of maximum flowAdjust it by loosening the hexagonnut(808) and by tightening(Or loosening)the set screw(954).The maximum flow only is adjusted withoutchanging other control characteristics.

Adjustment of maximum and minimum flows

Adjustment of minimum flowAdjust it by loosening the hexagon nut(808) and by tightening(Or loosening) thehexagonal socket head set screw (953). Similarly to the adjustment of themaximum flow, other characteristics arenot changed. However, remember that, if tightened toomuch, the required horsepower duringthe maximum delivery pressure(Orduring relieving) may increase.

Delivery pressure, PiDe

liver

y flow

, Q

Delivery pressure, Pi

Deliv

ery f

low, Q

808

954

808

953

(4)

Adjustment of min flowTightening amountof adjusting screw

(953)

(Turn)

+1/4

Flow changeamount

(/min)

-3.5

Speed

(min -1)

2200

Adjustment of max flowTightening amountof adjusting screw

(954)

(Turn)

+1/4

Flow changeamount

(/min)

-3.5

Speed

(min -1)

2200

2 - 19

79

1615767778

64

6

32

3334

25

89

3635

58

15

27

26

15 25

28

15

25

121319

6

17181516

2423

14 6870

6766576 5665

576 5674

2 1

6667576 56734445

2 432930

312930

31

98

15

58

69

675

393826

8 925

37

87

86

85

34

576 56

81212423

80

83829 8

40

42

31

1 Cap2 O-ring3 Socket bolt4 Spring washer5 Overload assy6 O-ring7 Orifice8 Cap9 O-ring10 Cover11 Socket bolt12 Sleeve13 Check

14 Cap15 O-ring16 Cap17 Spring18 Spring guide19 Spring guide20 Cap21 Spring22 Check23 Cap24 O-ring25 O-ring26 O-ring

27 O-ring28 Housing29 O-ring30 Retainer31 Socket bolt32 Plunger assy(TS)33 Plunger assy(TL, TR)34 Plunger assy(SW)35 Plunger assy(BM2)36 Plunger assy(AM1)37 Cover assy

1. STRUCTURE(1/2)GROUP 2 MAIN CONTROL VALVE

2 - 20

STRUCTURE(2/2)

26

55566 576667

40

42

5453

7356 6576966

7156657

6667

49

4847

46

756

12

3 4

89

50

62616059

1615767778

42

3351

52

3189

6358

15

24

12

2930

31

23

89

15

58 2930

312930

31

98

22

621

20

84

7

72

94 159395

41

11

1092

91888990

A

A

5

38 Spring39 Poppet40 Cover41 Manifold42 O-ring43 Cap44 Spring45 Spool46 Plug47 O-ring48 Retainer49 Socket bolt50 Housing51 Plunger assy(OPT)52 Plunger assy(BKT)

53 Plunger assy(BM1)54 Plunger assy(AM2)55 Cap56 Back up ring57 Nylon chip58 Overload assy59 Spring60 Check61 O-ring62 Back up ring63 Cap64 Main relief assy65 Cap66 Spring67 Check

68 Spacer69 Cover70 Piston71 Cap72 Check73 Cap74 Cap75 Foot relief assy76 Plug77 Back up ring78 O-ring79 Cap80 Spacer81 Check82 Spring

83 Spool84 Stopper85 Selector assy86 O-ring87 O-ring88 Spring guide89 Spring90 Poppet91 O-ring92 Back up ring93 O-ring94 Back up ring95 O-ring

2 - 21

2. FUNCTIONHYDRAULIC CIRCUIT

XAk2Pal dr8 dr2 frflCk1

Pz P1 Px Py P2 R

Pi

320K(350K)

XAah

Aa1Ba1XAa1

XBa2

XBa1XAas

Op

XBb2

dr6

XAsBs

As

XBs

BtlAtlXAtl

XBtl

XAa2

XBa2

dr4

5Pi

Bb1

XBb1XBb2

Ak1Bk1 XAk

XAk2

XBk

Ck2

AtrBtr

AoBo

XBo

XAo

XAtr

XBtr

Ab1XAb1

ARM1

BOOM2

SWING

TRAVEL(LH)

ARM2

BOOM1

BUCKET

OPTION

TRAVEL(RH)

1)

2-22

(1) Bucket flow summation circuit

P2 P1

BKT

P1 P2Pp

FrFl

P2P1

XAk2

Center bypass valve

To tank passage throughfoot relief valve

Ck1Spool B

TR

OPT

BKT

BM1

AM2

TL

SW

BM2

AM1

Bk1 Ak1

Ck2

XAk

R

TS

BASIC OPERATION

Bucket flow summation circuitOil from pump P2 is fed into cylinder portAk1 by adding pressure to bucket plungerpilot port XAk and the oil from actuatorflow tank through cylinder port Bk1.The center bypass valve is changeoverby the pilot pressure XAk2 and the oilfrom center bypass passage flows to thebucket summation port Ck2 via outsidepiping and some others flow into footrelief valve. Then the oil form pump P1 is joins to theflow from the pump P2 via confluencepassage.

2)(1)

2-23

(2) Swing priority circuit

P1 P2Pp

FrFl

AM-2AM-1

SW

P2 P1

TR

OPT

BKT

BM1

AM2

R

TL

SW

BM2

AM1

TS

P1P2

As Bs

XBs

SW

AM2

XAa2

XAa1

AM1

XAasBa1 Aa1

Swing priority circuitOil from pump P1 is fed into cylinder portBs via center bypass passage by addingpressure to swing plunger pilot port XBs.In case of simultaneous operation ofswing and arm, the delivery oil from P1 forswing is also supplied to arm cylinder portAa1.Meanwhile the pilot oil form the swingshuttle valve flows into stroke limiter portXAaS of arm spool, then the arm1plunger does not full stroke. Consequently, the swing priority ismaintained.

(2)

2 - 24

OPERATIONAL DESCRIPTION OF CONTROL VALVE

Plunger operationNeutral position of plunger

In neutral, spring sets the plunger at the neutral position; The high pressure feed passage is shutoff by the plunger; Oil from the pump flows through the center bypass.

3)(1)

Parallel feed passage

Cylinder port B

Pilot port b

Low pressure passage

Center bypass passage

High pressure feed passage

Pilot port a

Cylinder port A Port relief valve

SpringLow pressure passage

Port relief valve

2 - 25

Operation of plunger

When actuated(Pressure is applied to pilot port a), the plunger moves to the left, the centerbypass is shut off; Oil from the parallel feed passage opens the check valve C1 and flows intocylinder port A via the high pressure feed passage.The return oil from cylinder port B flows into the tank via the low pressure feed passage.Reversed when pressure is applied to pilot port b.


Cylinder port B

Pilot port b




Pilot port a

Cylinder port A Port relief valve

SpringLow pressure passage

Port relief valve

2 - 26

Foot relief valve operationfp is lower than spring force

Oil from the center bypass valve flows into the tank via orifice(A) of poppet.Pressure fp generated by orifice(A) is led to the pump, to control the pump delivery flow.

fp is higher than spring force

If a large amount flows due to delayed pump response, etc., and pressure fp reaches the presetspring force, then the poppet is lifted and functions as a relief valve.

(2)

Poppet

A

From centerbypass valve

fp To tank passage

Pressure signalsent out to the pump

Spring

Poppet

A

From centerbypass valve

fp To tank passage

Pressure signalsent out to the pump

Spring

2 - 27

Center bypass valve operationPilot pressure signal : OFF

Spring(B) sets spool(A) in position; Oil from center bypass flows into the tank passage via thefoot relief valve.

Pilot pressure signal : ON

When pilot pressure reaches a preset spring force, the spool(A) moves left and orificed the flowto the foot relief valve.Then the oil from center bypass flow into bucket summation port Ck2 via out side piping.

(3)

Spool(A)Drain line

From center bypass

To tank passage via foot relief valve

Spring(B)

Pilot signalport(XAk2)

Spool(A)Drain line

From center bypass

To tank passage via foot relief valve

Spring(B)

Pilot signalport(XAk2)

To bucket summation port(Ck2)

2 - 28

Main relief valve operationHigh pressure setting pilot signal : OFF

This relief valve is built in between the pump port side(1) and low pressure passage.Piston(E) is seated right end by spring(C).Hydraulic oil from the pump port side enters chamber(3) via orifice(2) of main poppet(A).Because d2

2 - 29

When the above oil flow is formed, pressure drops before and behind orifice(2) ; Whenpressure of chamber(1) x area d2 is large than pressure of chamber(3) x area d1, mainpoppet(A) is opened and hydraulic oil flows into the low pressure passage.

High pressure setting pilot signal : ON

Piston(E) move to left by high pressure setting pilot signal ; Set pressure of spring(C) rises,making high pressure setting.

Low pressure passageMain poppet(A)

(Pz)

Pilotsignal : ON

Piston(E)

Spring(C)

C.

1 2 3

d2d1

2 - 30

Overload relief valve operationOverload working operation

Hydraulic oil from cylinder port enters chamber(2) via orifice(3) of piston(A). Because d1

2 - 31

Hydraulic oil from chamber(1) enters chamber(2) via throttle(6) at the tip of pilot poppet(E) ; Itflows into the low pressure passage via side hole(4) and passage(5).

Pressure drops before and behind throttle(6), making pressure of chamber(1) x aread1>pressure of chamber(2) x area d2 ; Main poppet(B) is opened and hydraulic oil flows intothe low pressure passage.

D.

E.

Pilot poppet(E)

Spring(D) Main poppet(B)

Poppet(C)

Piston(A)

1d3d1

54Low pressure passage

d2d46

Cylinder port

2 - 32

Make up operation

Poppet(C) is securely seated because the cylinder port pressure is normally higher than thetank pressure and d3

2 - 33

Arm regeneration operationArm operation

When pressure is applied to pilot port XAa1 of the arm plunger, the plunger moves to right asshown ; The center bypass passage is shut off ; Oil from the parallel feed passage opens checkvalve(C1) and flows into cylinder port Aa1(Head side) via the high pressure feed passage.

(6)


Pilotport


Spool(B) Spring(C)



2 1 3 4

(PB)

C2C1

(PA)

Tank passageBa1Aa1

Piston(A)

XAa1

2 - 34

PB is higher than PA

PA : Pressure of cylinder head sidePB : Pressure of cylinder rod side

Return oil from cylinder rod side opens check valve(C2) in the plunger ; It flows into cylinder headside after returning to the high pressure feed passage via passage(1) and (2) in the plunger.At this time, the regeneration selector spool(B) is at the shown position; as passage(3) is shut offfrom passage(4) return oil from cylinder rod side does not flow into the tank passage.


Pilotport


Spool(B) Spring(C)



12 3

(PB)

C2C1

(PA)

4

Tank passageBa1Aa1

Piston(A)

XAa1

2 - 35

PA is higher than PB

Return oil from cylinder rod side is shut off by check(C2) in the plunger and passage(2) isblocked from passage(1).When pressure PA rises higher than the preset pressure of spring(C) and pushes piston(A) in theregeneration selector to right as shown ; Spool(B) move to right ; Passage(3) and passage(4) areconnected ; Return oil from cylinder rod side flows into tank passage via low pressurespassage(3) and passage(4).


Pilotport


Spool(B) Spring(C)



12 3

(PB)

C2C1

(PA)

4

Tank passageBa1Aa1

Piston(A)

XAa1

2 - 36

Arm holding valve operationWhen the plunger is in neutral(4Pi pilot signal : OFF)

Piston(A) is in the status as shown ; Pressure signal(Pg2) and chamber(Y) are shut off.Thus piston(B) and poppet(C) are in the status as shown;Passages(5) and (6) are shut off bypoppet(C).Therefore, the pressure of chamber(1) becomes pressure Pc as it is connected with chamber(2)via orifice(4). Since d1>d2, poppet(E) is seated and chambers(2) and (3) are completelyblocked.

(7)

Drainport

d1

d2

High pressurefeed passage

Tank passage

3(Pv)2(Pc)

1

Z

VIEW Z

7Arm1 plunger

To armcylinder rod(Ba1)

4

Poppet(E)

56

Piston(B)Poppet(C)Check(D)

Pg2

4Pi

Pilot signal portPiston(A)

Y

2 - 37

When the plunger is in operation(4Pi pilot signal : OFF)If Pv is higher than Pc(In the case of arm out)

When the plunger moves to left, the high pressure oil enters to chamber(3).Therefore, the pressure of chamber(1) becomes Pc as it is connected to chamber(2) viaorifice(4) ; Poppet(E) is opened ; Oil from high pressure feed passage flows into the cylinderrod side.

Drainport

d1

d2


Tank passage

3(Pv)2(Pc)

1

Z

VIEW Z

7


4Poppet(E)

56


Pg2

4Pi


Y

2 - 38

If Pc is higher than Pv(In the case of arm in operation)

When the pressure of pilot signal enters, piston(A) moves to down. When the pressure signal(Pg2) enters to chamber(Y), piston(B) moves to left and poppet(C)opens ; Passages(5) and (6) are connected.If pressure Pc of cylinder port chamber(2) is higher than pressure Pv of chamber(3)(In thecase of arm in operation) oil from chamber(1) pushes up check valve(C) via passages(5) and(6) and enters chamber(3) through passage(7). Chamber(3) is connected with the tankpassage because the arm plunger is moved to right. Therefore, pressure Pc is applied to(Aread1- area d2), pushing open poppet(E), and return oil from the cylinder rod side flows into thetank passage.

Drainport

VIEW Z

7

6


Pg2

4Pi


Y

d1

d2


Tank passage

3(Pv)2(Pc)

1

Z


4Poppet(E)

5

2 - 39

Boom holding valve operationWhen the plunger is in neutral(5Pi pilot signal : OFF)

Spool(A) is in the status as shown ; Chamber(1) and drain port(dr4) are shut off by spool(A).Therefore, the pressure of chamber(1) becomes pressure Pc as it is connected with chamber(2)via orifice(4). Since d1>d2, poppet(B) is seated and chambers(2) and (3) are completely blocked.

(8)

1

3(Pv)

2(Pc)

4

5PiPilot signal port

dr4

Bb1

To boomcylinder head

Boom1

Tank passage High pressurefeed passage

Spool(A)

Poppet(B)

d1

d2

2 - 40

When the plunger is in operation(5Pi pilot signal : OFF)If Pv is higher than Pc(In the case of boom raise)

When the plunger moves to right, the high pressure oil enters to chamber(3).Therefore, the pressure of chamber(1) becomes Pc as it is connected to chamber(2) viaorifice(4) ; Poppet(B) is opened by pressure(Pv) of chamber(3) ; Oil from high pressure feedpassage flows into the cylinder head side.

1

3(Pv)

2(Pc)4


dr4

Bb1

To boomcylinder head


Spool(A)

Poppet(B)

d1

d2

2 - 41

If Pc is higher than Pv(In the case of boom down operation)

When plunger moves to left, chamber(3) is connected with tank passage. At the same time,spool(A) moves to right by the pressure of pilot signal ; Chamber(1) and drain port(dr4) areconnected. Therefore, pressure of chamber(1) becomes low ; Pressure Pc is applied to(Area d1- area d2),pushing open poppet(B), and return oil from the cylinder head side flows into the tankpassage.

1

3(Pv)

2(Pc)

4


dr4

Bb1

From boomcylinder head


Spool(A)

Poppet(B)

d1

d2

2-42

1. STRUCTURESwing device consists swing motor, swing reduction gear.Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.

GROUP 3 SWING DEVICE

PgSh

A B

PA PBMu

Dr3

X

View X

Grease filling port

Reduction gear

Sh

Pg

Mu

PB

dr3

PA

A B

Hydraulic circuit

Time delay valve

Swing motor Relief valveGear oil drain port

Port

ABdr3MuShPg

PA,PB

Port name

Main portMain portDrain portMake up portBrake release portStand by portGauge port

Port size

PF 3/4PF 3/4PF 3/8PF 3/4PF 1/4PF 1/4PF 1/4

2-43

SWING MOTOR

031 Time delay valve031-1 Plug051 Relief valve assembly

051-1 O-ring100 Casing101 Drive shaft111 Cylinder113 Retainer ring114 Spring116 Push rod117 Spacer118 Spacer121 Piston122 Shoe123 Plate124 Shoe plate131 Valve plate151 Plug

161 O-ring162 O-ring163 O-ring171 Hexagon socket bolt301 Casing303 Valve casing305 Seal cover351 Plunger355 Spring400 Reactionless valve

400-1 O-ring400-2 Back up ring401 Hexagon socket bolt437 Snap ring438 Snap ring443 Roller bearing444 Roller bearing451 Pin

464 Plug469 Plug472 O-ring485 O-ring488 O-ring491 Seal702 Brake piston706 O-ring707 O-ring712 Brake spring742 Friction plate743 Separate plate981 Plug984 Plug993 Plug994 Plug

116 118 114 031 031-1 706 707 702 712 472 981 438 303 052

151161

171

162

163

981444984131451

485464111743742121113122994123

301

124

491101

443

437

305

117

400 400-2 400-1

469 488 355 351

051 051-1 993

A

A

SECTION A-A

100

401

1)

2-44

REDUCTION GEAR

102 Casing201 Drive shaft202 Ring gear203 Planetary gear 2204 Sun gear 2210 Planetary gear 1211 Sun gear 1230 Carrier 2231 Carrier 1282 Pin

283 Pin285 Side plate286 Side plate287 Side plate288 Side plate311 Level bar312 Pipe401 Roller bearing402 Roller bearing403 Needle cage

602 Hexagon socket bolt801 Seal 901 Plug902 Plug910 Spring pin911 Snap ring912 Snap ring913 Snap ring915 Bearing seal

915201 401 902 901 202102

602231204287211912

283911285

403

210

288282203286910

230913402

801

311312

2)

2-45

2. FUNCTIONROTARY PARTWhen high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(131),hydraulic pressure acting on the piston causes axial force F. The pressure force F works via thepiston(121) upon the return plate(123) which acts upon the swash plate(124) via an hydrostaticbearing. Force F1 perpendicular to swash plate(124) and force F2 perpendicular to cylinder center.Being transferred to the cylinder block(111) through piston, force F2 causes rotational moment atsurroundings of cylinder.Since cylinder block has 9 equidistantly arrayed pistons, rotational torque is transmitted to cylindershaft in order by several pistons connected to the inlet port of high pressurized oil. When thedirection of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque isgiven by the equation.

pq FT = , q = ZAPCDtan, F1 = , F2=F tan, S=PCDtan

2 COSWhere p : Effective difference of pressure(kgf/cm2)

q : Displacement(cc/rev)T : Output torque(kgfcm)Z : Piston number(9EA)A : Piston area(cm2): Tilting angle of swash plate(degree)S : Piston stroke(cm)

Lowpressure oil

F1

FF2

124 123 121 111

131

Highpressure oil

1)

2-46

MAKE UP VALVEIn the system using this type of motor, there is no counter balance functioning valve and therehappens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitationcaused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.A make up valve is provided immediately before the port leading to the hydraulic oil tank to securefeed pressure required when the hydraulic motor makes a pumping action. The boost pressureacts on the hydraulic motor's feed port via the make up valve.Pressurized oil into the port B, the motor rotate counterclockwise.If the plunger of MCV moves neutral position, the drain oil from Mu port run into motor via rightmake up valve, which prevent the cavitation of motor.

2)

Mu

A B

2-47

RELIEF VALVE

Construction of relief valveThe valve casing contains two cartridge type relief valves that stop the regular and reverserotations of the hydraulic motor. The relief valves relieve high pressure at start or at stop of swingmotion and can control the relief pressure in two steps, high and low, in order to insure smoothoperation.

Function of relief valve Figure illustrates how the pressure actingon the relief valve is related to its risingprocess. Here is given the function,referring to the figure following page.

322

303

321301

Time

Relief pressure

Ps

P2P1

1

2 3

4

3)

301 Plunger303 Piston 321 Spring322 Spring

(1)

(2)

2-48

Ports(P,R) at tank pressure.

When hydraulic oil pressure(PA1) reaches the preset force(FSP) of spring(321), theplunger(301) moves to the right as shown. Also the oil flow chamber g via orifice m.P1A1=Fsp+PgA2

Fsp+PgA2P1 = A1

301

m

P

R

g h321

303 322

A1 A2 A3

301

P=P1

gm 321

2-49

When the pressure of chamber g reaches the preset force(FSP) of spring(321), the piston(320)moves right and stop the piston(320) hits the end of body.

When piston(320) hits the end of body, it stops moving to the right any further. As the result, thepressure in chamber g equals Ps.PsA1=Fsp+PsA2

FspPs = A1-A2

P=P2

gm 321 320

P=Ps

gm 321 320

2-50

BRAKE SYSTEM

Control valve swing brake systemThis is the brake system to stop the swing motion of the excavator during operation.In this system, the hydraulic circuit is throttled by the swing control valve, and the resistancecreated by this throttling works as a brake force to slow down the swing motion.

(1)

Mechanical swing parking brake systemThe mechanical swing parking brake system is installed to prevent the upper structure fromswinging downhill because of its own weight when the excavator is parked on a slope since itcompletely eliminates the hydraulic drift of swing motion while the excavator is on a slop, work canbe done more easily and safely.

Brake assemblyCircumferential rotation of separateplate(743) is constrained by the groovelocated at casing(301). When casing ispressed down by brake spring(702)through friction plate(742), separateplate(743) and brake piston(702), frictionforce occurs there.Cylinder(111) is constrained by thisfriction force and brake acts, while brakereleases when hydraulic force exceedsspring force.

Work Deceleration Stop

MCV A, B opened MCV A, B throttled MCV A, B closed

MCV MCV MCV

A B A B A

712

702301111743

742

111 Cylinder301 Casing702 Brake piston

712 Brake spring742 Disc743 Separate plate

4)

(2)

2-51

Operating principleWhen the swing control lever(1) is set to the swing position, the pilot oil go to the swing controlvalve(2) and to Sh of the time delay valve(3) via the shuttle valve(4), this pressure shift timedelay vlave so, pilot pump charged oil(P3) go to the chamber G.This pressure is applied to move the piston(702) to the upward against the force of thespring(712) thus releasing the brake force.

5

P3

2 24

1

Sh

3

G702

712

1 Swing control lever2 Swing control valve(MCV)3 Time delay valve4 Shuttle valve5 Pilot pump

702 Brake piston712 Brake spring

a.

2-52

When the swing control(1) lever is set the neutral position, the time delay valve(3) shifts theneutral position and the pilot oil blocked chamber G.Then, the piston(702) is moved lower by spring force and the return oil from the chamber G isdrain.

Sh

3

G702

712

5

P3

2 24

1

1 Swing control lever2 Swing control valve(MCV)3 Time delay valve4 Shuttle valve12 Pilot pump702 Brake piston712 Brake spring

b.

2-53

1. CONSTRUCTIONTravel device consists travel motor and gear box.Travel motor include counter balance valve, cross over relief valve.

GROUP 4 TRAVEL DEVICE

P1T2 P2 T1

VIEW A VIEW C

A

C

Level

Drain

Filling

T1(T2)Ps

P1 P2

R/G

a2

Hydraulic circuit

a1

Ps

a1a2

Port

P1P2a1a2T1T2Ps

Port name

Main portMain portGauge port(For P1)Gauge port(For P2)Drain portDrain port2 speed control port

Port size

PT 3/4PT 3/4PT 1/4PT 1/4PF 1/2PF 1/2PT 1/4

2-54

TRAVEL MOTOR(1/2)1)

25

VIEW A

RELIEF VALVE DETAIL

26 23 27 28 22

3029

242120171831

32

19

433338

373536

116

14

1544

8

394041

34

2

3

67

5

410

1342

1211

9

1 Base plate2 Plunger3 Check valve4 Spring5 Plug6 O-ring7 Cap8 O-ring9 Socket head bolt10 Steel ball11 Spring12 O-ring13 Plug14 Spring seat15 Spring16 Relief valve assembly

17 Relief housing18 Poppet19 Poppet seat20 Spring seat21 Spring22 Plug23 O-ring24 Free piston25 O-ring26 Back up ring27 Spring guide28 O-ring29 Set screw30 Nut31 O-ring32 Back up ring

33 Plug34 Spool35 Spring36 Plug37 O-ring38 Orifice39 Orifice40 O-ring41 Plug42 Plug43 Orifice44 Flange

2-55

TRAVEL MOTOR(2/2)

69

47 4948

5051 52 53

5455

5670 79 57 58

59

60

66

61

75

62

81

63

64 7382 65 79 72 71 80

81

76 83 74 78 77 6768

A

47 Casing48 Shaft49 Spring pin50 Cylinder block51 Piston assembly52 Retainer plate53 Retainer holder54 Snap ring55 Collar56 Spring57 Collar58 Pin59 Swash plate

60 Steel ball61 Piston assembly62 Roller bearing63 Roller bearing64 Spring pin65 Socket head bolt66 Oil seal67 Disc plate68 Brake piston69 O-ring70 Back up ring71 O-ring72 Back up ring

73 Spring74 Pin75 Spring76 Valve plate77 Orifice78 O-ring79 O-ring80 Plug81 Plug82 Plug83 Socket head bolt

2-56

11-11-21-31-41-51-62

2-12-22-32-42-52-63

3-1

Holder A assemblyHolder APlanet gear ANeedle bearingGear shaft AThrust washerSpring pinHolder B assemblyHolder BPlanet gear BNeedle bearingGear shaft BThrust washerSpring pinHolder C assemblyHolder C

3-23-33-43-53-63-73-84568910111213

Planet gear CRoller bearingGear shaft CFloating bushingCollarThrust washerSpring pinDrive gearThrust plateSun gear BSun gear CSpring washerFlangeFloating sealAngular bearingHousing

141516171819202122232425262728

Shim(0.1~0.05t)PinSocket head boltSocket head boltPlateRing gearO-ringSocket head boltPinThrust plate(1.8~3.2t)CoverSocket head boltPlug(PF 3/4)Plug(PT 1/4)Plug(PT 1/8)

2) REDUCTION GEAR

-1 -4 -3 -2 -5 -6

2

28

10

11 12 15 14 22 20 -6 -2 -4 -5 -7 -3 -8 -1

3

19

24

29

26

5

23

64

8

-1

-2

-5

-3-4

-6

1

25

13 17 18 27 9 16 21

2-57

2. FUNCTIONHYDRAULIC MOTOR

Rotary group

1)(1)

The cylinder block contains nine pistons. The end face of the cylinder block is in contact with thevalve plate that has two semicircular ports B and C(Distributor valve that changes over high andlow pressures).Principle of generating torqueIf high pressure oil(Pressure P) is admitted to port P,force F(=PXA, A : Cross-sectional area of apiston) per piston acts on the shaft and generates radial component Ft. As the result, the totalsum of radial forces of the pistons on the high pressure side produces a rotating torque in thedirection of the shaft.Inversely, if high pressure oil is admitted to port C, the motor turns in the opposite direction.The output torque and revolution of the motor available by the above-mentioned principle dependupon pressure(P) and inflow rate(Q) supplied to the motor and are calculated as below:Output torque

T= PDm2100

(kgm),

PistonValve plate

Shaft

Cylinder blockX

X

N = Q1000vD

(rpm),

Where ; D : Displacement capacity(cc/rev)P : Effective drive pressure(kg/cm2Q : Incoming flow(/min)m : Mechanical efficiency(%10-2)v : Volumetric efficiency(%10-2)

(1)

(2)

2-58

COUNTER BALANCE VALVE

Neutral position

2)(1)

Counter balance valve controls according to oil supply so as to prevent reckless of running of the motor.When the control valve is in neutral position, oil does not supply the port P1 and P2.This blocks the motor port to prevent the motor from rotating.

Control valve

P1

P3

P2

M1 M2

2-59

Counter balance function(2)

Control valve

P1

P3

P2

M1 M2

Oil discharged from main pump flows into the counter balance valve port P1 via control valve.The oil flows into piston motor via check valve and M1 port.Since the return oil from motor port M2 is blocked by check valve, the pressure of port P1 isincreased.Accordingly, the pressure applied through the orifice to left chamber of plunger and moveplunger rightward.Port M1 is connected by notch of plunger to port P2, then the return oil of motor port M2 isdischarged, and the travel motor starts revolution.Reversed when hydraulic oil pressure is applied to port P2.

2-60

When the travel lever return to neutral position, the oil from the main pump is blocked, and the plungerreturn the neutral position by spring force.But the motor is rotated by inertia, so the pressure at the output port of motor rises, then motor isbraked.If the pressure reaches the set pressure of relief valve, oil flows into port M1. As a result, the shockpressure caused by inertia force is released and prevent cavitation of port M1.

Brake function(3)

P1

P3

P2

M1 M2

2-61

Function of reliefFigure illustrates how the pressure actingon the relief valve is related to its risingprocess. Here is given the function,ref

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